Modeling of processes and components

Our simulation team supports you with validated material models, proven calculation routines, and customized simulations with advanced material models.

MCL is your expert partner for mapping and modeling complex manufacturing and stress processes. We combine many years of experience in materials testing with in-depth expertise in numerical simulation to deliver realistic, reliable, and practical results.

Let us work together to virtually map your manufacturing processes and product applications—for efficient workflows, robust components, and reliable products.

We offer solutions for:

Product simulation & optimization
Thermal and mechanical stress, simulations of contact processes (friction, contact fatigue)/stress analysis, service life optimization, and product optimization using virtual sensors and comparison with field measurements
Modeling of manufacturing processes
Efficient manufacturing processes through simulation-based analysis across all scales
Multiphysical systems
Precise simulation and optimization of multiphysical systems, taking into account interactions between mechanics, thermodynamics, electromagnetism, and other physical effects
Computational Fluid Dynamics (CFD)
Mapping of flows and complex fluid behavior to determine and optimize process variables and components

Our services in detail

Product use simulation

Product optimization of components, even in complex contact situations (friction, contact fatigue, etc.)
Product optimization using virtual sensors and comparison with measurements in the field
Insight into the interior of products during manufacturing and operation
Service life optimization and reduction of inspection intervals through increased knowledge of materials and stress
Time-efficient product optimization and reduction of testing effort

Calculation services for design and development

MCL is happy to support its customers in implementing their ideas in the field of component development and design.

Our main areas of focus are:

Simple, fundamental calculation studies for a better understanding of the load situation.
Standard-compliant design of technical components.
Nonlinear calculations with complex material behavior and changing contact conditions.

MCL also offers customized tools for your simulation department for automated and user-friendly creation and evaluation for the FE software packages Abaqus, Deform, and Ansys.

Our range of services

Stress and fracture mechanics component design Load and damage analysis
- Fatigue and endurance strength analysis
- Standard-compliant design (DIN, VDI, FKM, ASME, BS, FITNET, etc.)
- Fitness for purpose (proof of suitability for use) Damage tolerant design
- Numerical estimation of crack growth rates
- Accompanying calculations during the design phase
Thermomechanical problems
- Die casting molds and mold frames
- Brake discs
- Furnace housings
- Electronic components
- etc.
Complex contact problems
- Contact pressure and contact opening
- Contact fatigue
Automation and customization of pre- and post-processing (Abaqus, Deform, and Ansys)
- Pre-built tools for customer calculations
- Scripts & plug-ins

Simulation of manufacturing processes

Development of efficient processes and process chains
Improvement of material and component properties through optimization of the manufacturing process
Modification of material properties through targeted heat treatment
Improvement of the dimensional accuracy of components

MCL has been conducting research in the field of process chain simulation for many years and therefore offers the following services:

Simulation of heat treatment and forming processes
Stress analysis and service life extension of tools

In many cases, the manufacturing process of a component has a major impact on the behavior of the component in use.

An important goal of process chain simulation is to obtain information about changes in geometry, chemical composition, distribution of hardness, microstructure, and residual stresses, as well as any pre-damage.

We are happy to support you with FE analyses of tools and work with you to develop an optimization strategy with regard to geometry, material selection, and the parameters of the manufacturing process.

Our range of services

Heat treatment (WBH) Microstructure and hardness distribution
- Residual stresses
- Distortion
Diffusion calculation Thermomechanical surface treatments (nitriding, carburizing, etc.)
- Calculation of concentration distributions
- Forming Feasibility analyses
Pre-damage caused by forming processes
- Compaction of powder metallurgical components
Tool loading and service life extensionForming tools
- Casting molds and mold frames
- Drills
- etc.

Multiphysical systems

Combination of thermal and mechanical stress
Nonlinear electromagnetic material behavior in thermomechanical processes (e.g., spot welding, induction)
Hydrogen diffusion and embrittlement
Phase transformation, TRIP effect
Crystal plasticity

Computational fluid dynamics (CFD)

The CFD Group specializes in the simulation and description of fluid mechanics problems in industrial processes. Our broad range of expertise allows us to handle complex industrial projects in a timely manner and to implement customer-specific problems in our own software packages.